Molded cladding for building structures

ABSTRACT

A molded cladded panel comprises on the underside thereof a bearing surface formation for bearing on an underlying support surface and latches for latching the panel to an underlying support surface, the panel having a profile configured to provide a desired appearance rising above the bearing surface formation, a nib formed on the profile for interfitting with adjoining panels whether in end-to-end or side-by-side relation, and a latched keeper member for latching engagement with the panel latches.

FIELD OF THE INVENTION

The present invention relates to cladding for use in housing and otherbuilding structures. More particularly, the invention provides a novellow cost, endurable cladding particularly adapted for the roofing ofhouses and other buildings not only to provide an enhanced appearance tothe roof and building but also providing important functional advantagesto protect the roof from the elements.

In this connection, the novel cladding of the present invention hasparticular application to the cladding of the roofs of housing and otherbuilding structures erected utilizing the building system and componentstherefor as disclosed and claimed in my copending U.S. application Ser.No. 08/338,605 which for the first time enables the erection ofpermanent, affordable, high quality housing and other buildingstructures essentially totally from polymeric components which can beeasily and rapidly assembled essentially without the use of tools toprovide an essentially indestructible maintenance free structure.

In particular, the structural components of the said novel buildingsystem comprise extruded thermoplastic components with structural loadbearing members incorporating a reinforcing constituent impartingstructural strength and expansion control thereto and flowable with thethermoplastic material through an extrusion die to produce an integral,essentially rigid structural shape configured to present means forinterconnection with adjoining structural components.

Such components include extruded rectilinear hollow panels and beamshaving internal cells and hollow box connectors extruded to have athermoplastic core or substrate having reinforcing and expansioncontrolling material distributed therethrough and a coextruded smooththermoplastic skin on the exposed exterior surfaces of said core. Asdisclosed in said copending application, particularly advantageousreinforcing material for incorporation and distribution throughout thecore substrate consisting of vinyl chloride, eg. a polyvinyl chloride,comprises fine, short glass fibers with the said skin embedding andinterlocking with the glass fiber portions that are exposed at thesurface between the reinforced core and co-extruded skin.

A suitable glass fiber containing core material providing structuralstrength and expansion control may be obtained from B. F. GoodrichCompany of Akron, Ohio, such material being described in detail in B. F.Goodrich's U.S. Pat. No. 4,536,360.

The coextruded skin may, for example, be PVC, rigid PVC, semi-rigid PVS,or ABS. Suitable skin thermoplastics are available from G.E. under thetrade-marks "GELOY" or "NORYL".

According to the present invention, the cladding is provided by theassembly of a plurality of injection molded mating panels configured tointerfit with each other and each having latch means at the undersidethereof for latching same to an underlying cooperative latching means orkeeper.

Further, accordingly to the invention, each panel member is formed atthe underside thereof with spaced bearing surface or points for beatingon an underlying support when the panel is latched to the underlyingkeeper, said panel member having a profile spanning said spaced bearingsurfaces or points and having a profile rising thereabove and configuredto provide a desired ascetic appearance.

Further, according to the invention, the panels by virtue of their saidprofile are adapted when interfitted to provide airflow channels for aircirculation therebeneath. In this connection, the invention furthercontemplates the provision of screening to interfit with the panels atthe ends of the airflow channels to block the entrance thereto of birds,insects, sleet, snow or the like.

A particular application of the invention as described herein is theprovision of panels simulating roofing dies, for example, SpanishRoofing tiles, to form tiled roofing for thermoplastic housing or otherbuilding structures erected using the novel building system andthermoplastic components disclosed in my said copending U.S. applicationSer. No. 08/338,605 as discussed above.

Plastic roof tiles fasten to battens have been disclosed. For instance,Belgian Patent BE-A-643896 (Schmidt) dated Mar. 13, 1964 discloses aplastic roof file having a hook at its underside at end thereof toengage spaced roof battens by sliding the tile longitudinally towardsthe battens.

According to the present invention, a molded cladding panel having adesired profile is provided with a plurality of latches on the undersidethereof characterized in that each of the said latches comprises adepending tongue portion (24) having an integral barb (25) extendingupwardly of the lower end of the tongue portion at an acute anglethereto, the barb being resiliently compressible towards the tongueportion to enable same to pass through the entrance of a keeper (13) andthereafter spring back away from the tongue portion within the keeper.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood with reference to theaccompanying drawings illustrating representative embodiments of theinvention and in which:

FIG. 1 is a diagrammatic view of a house having a roof cladding appliedthereto in accordance with the invention, the cladding being in the formof a simulated Spanish Tile roof;

FIG. 2 is an exploded perspective view illustrating the manner in whichan individual tile panel is secured by an adapter to a roof structureformed from extruded thermoplastic components in accordance with mycopending application Ser. No. 08/338,605,

FIG. 3 is a perspective view of a panel incorporating 4 simulated tileformations together with starter strips assembled therewith providingscreening at the entrance thereto;

FIG. 4 is a perspective view of the underside of the tile panel andstarter strips of FIG. 3 and illustrating the integral latchingmechanism for snap locking with a roof mounted adapter;

FIG. 5 is a broken away perspective view of a preferred form of adapterfor connecting the roof tile panels to a roof structure such asillustrated in FIG. 2;

FIG. 6 is an end elevational view illustrating how the adapter of FIG. 5is constructed to interlock with a box connector used in joining theroof panels of the roofing structure illustrated in FIG. 2;

FIG. 7 is an enlarged exploded broken away perspective view showing amodified form of latching arrangement at the underside of a tile panelfor snap locking into a keeper channel in the adapter illustrated inFIG. 5;

FIG. 8 is a part diagrammatic part longitudinal view illustrating thetile interfit as the tile panels are arranged in end-to-end relation upthe slope of the roof and illustrating the interfit between the tilepanel and the starter strip at the entrance to the roofing tiles at theedge of the roof;

FIG. 9 is a front elevational view of a starter strip for a single tile;

FIG. 10 is an edge elevation of the starter strip of FIG. 9;

FIG. 11 is a perspective view of a starter strip to cover the entranceof two adjoining tile formations of a tile panel having a multiple oftile formations such as the tile panels of FIGS. 3 and 4;

FIG. 12 is an elevational view illustrating how adjoining rows of tilesgoing up the roof are arranged to overlap and showing a slightlymodified form of roof panel adapter.

FIG. 13 is a front elevational view of a ridge vent tile.

FIG. 14 is an exploded perspective view illustrating the manner in whichthe ridge vent tiles are adapted to overlap and to be assembled with thepanels applied up the roof and with the roof panel adapters;

FIG. 15 is an end elevational view of the overlapped roof ridge tiles.

FIG. 16 is a diagrammatic view illustrating the air flow passagesprovided up the roof and across the roof ridge by the arched tileformations of the tile panels and showing one particular roof slope;

FIG. 17 is a view similar to FIG. 16 but showing a different roof slopeand showing how the roof vent tiles accommodate such different roofslope and showing the roof panels filled with insulation.

DETAILED DESCRIPTION ACCORDING TO THE PREFERRED EMBODIMENTS

With reference to FIG. 1, a house 1 having sloping roof portions 2rising to a ridge 3 to define a gable 4 is provided with a roof tilecladding generally designated at 5 assembled from roof tile panelssecured to the roof by adapter members in accordance with the invention.

The invention is particularly applicable to the cladding of modularhouses or buildings erected from interlocking extruded thermoplasticpanels, box connectors and other extruded structural components andmembers such as referred to above as forming the subject matter of mycopending application Ser. No. 08/338,605.

As illustrated in FIG. 1, the assembled roof panels present a row ofsimulated roof files general designated at 6 overlapping end to end andrunning up the slope of the roof and roof ridge tile formationsgenerally designated at 7 extending in end-to-end relation along theridge of the roof with the ridge tile formations on opposite sides ofthe ridge overlapping to close over the ridge and present a tileformation running longitudinally of the ridge.

While the cladding of the present invention could be used to clad anyroof or other surface, it will be described with reference to itsparticular applicability to clad the roof structure as shown in FIG. 2.

In this connection, it will be seen that the roof 2 is formed ofextruded thermoplastic panels 8 shown with three internal cells 9connected by extruded box connectors 10 provided with projecting flanges11 having inturned fingers or ledges 12 for interlocking in end groovesin the panels 8.

The box connectors 10 illustrated comprise 4-way box connectors havingthe projected flanges and inturned fingers extending from all four sidesthereof with the arrangement at the bottom being available forinterlocking connection with a panel member or the like beneath the roofif desired, but a 3-way box connector could be used.

The provision of the flange and finger arrangement of the box connectoron the upper side of the roof 2, however, provides the means ofinterlockingly securing an extruded roof panel adapter 13 whichconstitutes a keeper for retaining and locking the roof tile panels tothe underlying roof as hereinafter more fully described.

In FIG. 2 the edge of the roof 2 terminates in an extruded roof panel 14adapted to interlock with the adjacent box connector 10 and providedwith means for interengagement with an injection molded edge roof tilepanel 15 which simulates a single tile formation.

FIG. 3 illustrates a main roof tile panel 16 simulating a row of tileconfigurations.

In both the roof tile panel 15 and the roof tile panel 16, the tileformations are defined by arched surfaces 17 provided at one end whichis to form the upper end going up the roof slope with projecting archedribs 18 with the height of the arched surfaces 17 decreasing towards theribbed end.

At the lower end the tile formations are provided with a flange 19 foroverlying and receiving the arched rib 18 of a tile formation of apreceding tile panel as shown in FIG. 8.

As illustrated in FIG. 3, the end of the tile formations defined by thearched surfaces 17 are closed by screens 20 carried by starter strips 21as illustrated in FIG. 11 and interlocked within the arched tileformations between ribs 22 as illustrated in FIG. 8.

As shown in FIG. 4, the arched surfaces 17 bridge over spaced bearingsurfaces 23.

As illustrated in FIG. 4, the two outer bearing surfaces 23 on theopposite sides of the center bearing surface are formed with downwardlyprojecting flanges, tongues or wings 24 which have spaced upwardly andoutwardly inclined locking barbs 25 to provide a snap interlock with theextruded adapter 13, the barbs being adapted to be resiliently flexedinwardly on entering the adapter and to thereafter spring outwardly tolock beneath the overlying surfaces.

Central flanges 26 extending downwardly from the center of the panel 16may be arranged to either be received within the adapter 13 as guides ormay bear on the roof panels 8 to give central support to the tile panel.

The underside of the roof panels preferably are formed with areinforcing ribbing arrangement 27 as illustrated in FIG. 4 for panel16.

The roof tile adapter 13 comprises a longitudinal extrusion which may,for instance, be extruded from PVC has, as shown particularly in FIGS. 5and 6, a central downwardly facing channel 28 within which is adownwardly projecting straight rib 29 and spaced therefrom a rib havinga downwardly projecting portion 30 and an upwardly inclined portion 31inclined towards the rib 29.

Outwardly of the central downwardly facing channel 28 are two upwardlyfacing channels 32 having ledge projections 33 partially closing theentrance to the channels.

As illustrated in FIG. 6, the adapter 13 is slidably interlockable withthe box connector 10 with the inturned finger or ledge of the boxconnector at one side being received between ribs 29 and 30 and with itsledge 12 interlocked behind the end of the upwardly inclined rib portion31.

It will be understood that with this arrangement the adapter 13 may onlybe interlocked in one way with the box connector as shown and will notinterlock with the flange and ledge of the box connector shown at thefight in FIG. 6 with the ledge facing in the opposite direction to thatin the locking connection.

It will be understood that the tile panels can be secured to theadapters 13 by forcing the barbed ends of the tongues or flanges 24downwardly with the locking barbs 25 being deflected inwardly in passingthrough the entrance to the selected upwardly facing channel 32 andthereafter resiliently snapping outwardly beneath the respective ledgeprojection 33'.

FIG. 4 illustrates the barbs 25 projecting from the same side of theircarrying flange or tongue 24. FIG. 7 illustrates an alternativearrangement in which the locking barbs 25' project on opposite sides ofthe carrying flange or tongue 24'.

It will be understood that the roof cladding by the panelling of thepresent invention is intended not only to provide a decorativeappearance but to provide protection for the underlying roof against theelements.

In this connection, the panels are injection molded using thermoplasticmaterials which will withstand the heat of the sun without deforming. Asuitable thermoplastic for this purpose is available from G.E. Plasticssold under the trade-mark "NOREL". Further the cladding panels,according to the invention, may be coated with an ultraviolet resistingcoating or paint as a protective measure.

For the other extreme, the outer surfaces of the panels may be providedwith small projections or nibs 34 as shown in FIG. 3 to prevent ice orother materials sliding off en masse.

FIG. 9 shows a start, or snip for closing the lower end of the lowermost single tile panel 15 comprising a base 21 and an arched screen 20which as seen from FIG. 10 presents an arched projecting rib portion 37which interlocks into the rib arrangement 27 in the interior of thepanel as illustrated in FIG. 8.

FIG. 11 illustrates a similar starter strip for use with the main panel16 which requires the use of two such starter snips in end-to-endrelation to close the entrances of the four tile formations.

FIG. 12 shows how the adjoining roof tile panels 15 and 16 overlap toprotect the underlying roof surface.

As illustrated, panel 15 has a laterally extending wing 39 shard tooverlap and interfit with the laterally extending wing 40 of the tilepanel 16.

Similar overlaps are provided between adjoining main panels.

FIG. 13 is a front elevational view of a ridge vent tile panel forinterfitting with the panel 16 and bridging in part across the ridge ofthe roof.

This tile panel 41 is provided with arched tile surfaces 42 adapted tofit over and engage with the arched ribs of the uppermost roof tile 16and is provided with an arched tile surface 43 having its axis extendinglongitudinally of the panel 41 and perpendicular to the axis of thearched surfaces 42.

Tile panel 41 is formed with downwardly projecting tongues or wings 44supporting depending locking barbs 45 adapted to interlock in the keeperchannels 32 of the adapters 13 as illustrated in FIG. 14.

As will be seen from FIG. 14 opposing ridge vent panels 41 are adaptedto overlap and close the ridge of the roof, the arrangement permittingthe tiles 41 to be used with roofs of different slopes as illustrated inFIGS. 15, 16 and 17.

It will be understood, however, that the opposing roof tiles 41illustrated in FIG. 14 may be formed as a single roof tile having acontinuous arch over the ridge of the roof. Such tiles would fit roofsof predetermined slopes and would be configured to match the particularslope of the roof to be covered.

In addition to the protection afforded by the roof tiles or claddingitself, as illustrated in FIG. 16, the raised or arched portions of thetile formations provide air passages for the circulation of air betweenthe tiles and the roof panels and along the ridge of the roof to affordadded protection of the ridge panels. Also as illustrated in FIG. 17,the root panels themselves may be filled with insulation 46 or otherinserts as desired.

While the invention has been particularly described with reference tocladding used for roofing and, in particular, roof tile cladding, itwill be understood that the invention is applicable to other forms ofcladding and to other surfaces.

For example, the adapter extrusion 13 can be secured to any roof or anysurface and injection molded panels configured to represent the desiredprotective or ascetic surface can be secured thereto by snapping thebarbed latches into the adapter keeper channels.

It will also be understood that variations in the detail may be madewithout departing from the scope of the appended claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A molded cladding panelhaving a profiled outer surface and an underside, said underside of saidpanel having at least one bearing surfaces and a plurality of latchesfor securing said panel to a surface to be clad, each of said latchescomprising a depending tongue portion projecting below and substantiallyperpendicular to said bearing surface and having an integral barbextending upwardly of a lower end of said tongue portion at an acuteangle to said tongue portion, and said barb being resilientlycompressible towards said tongue portion.
 2. A cladding panel as claimedin claim 1 in which said profile is formed with means for interengagingwith an adjoining panel.
 3. A molded panel as claimed in claim 1characterized in that the underside thereof has spaced bearing surfacesfor bearing on spaced keeper members on the surface to be clad, and saidbarbed tongue portions (24) extend downwardly from said bearingsurfaces.
 4. A molded panel as claimed in claim 3 characterized in thatsaid panel is shaped to simulate roofing tiles.
 5. A molded panel asclaimed in claim 4 characterized in that has an arched wall between saidspaced bearing surfaces and has a longitudinally extending wingformation extending laterally from a base of said arched wall at leaston one side thereof for overlapping engagement with a laterallyextending wing of a corresponding laterally adjoining panel.
 6. A moldedpanel as claimed in claim 4 characterized in that said panel has aplurality of laterally spaced longitudinally extending arched walls andhas further spaced bearing surfaces on the underside thereof providedwith said barbed tongues extending downwardly therefrom.
 7. A moldedpanel as claimed in claim 6 characterized in that said panel has appliedthereto an ultraviolet resistant coating.
 8. A molded panel as claimedin claim 6 characterized in that the upper surface, thereof has aplurality of spaced upwardly projecting integral nibs.
 9. A moldedcladding panel shaped to simulate a roofing tile, said panel having onthe underside thereof at least one set of spaced substantially parallelmounting means for supporting the panel on a roof and a plurality oflatches, depending from said mounting means, said latches eachcomprising a depending tongue portion having a integral barb extendingupwardly from a lower end of said tongue portion for securing said panelto a roof, said panel having an arched wall spanning between said set ofsaid mounting means with its axis parallel to said mounting means, andsaid panel further having an arched wall formation located at one end ofand with its axis substantially at right angles to the aforesaid archedwall.
 10. A molded panel as claimed in claim 9 in which said arched wallspanning said mounting means is provided adjacent to the end thereofopposite to said arched wall formation with an internal arcuate groovefor receiving an arched rib of an adjoining panel.
 11. A molded panel asclaimed in claim 9 or 10 having a plurality of pairs of parallel spacedmounting means with each pair of spaced parallel mounting means havingan arched wall having an axis substantially parallel thereto spanningtherebetween with each of said arched walls spanning between said spacedmounting means having at one end thereof an arched wall formation havingits axis substantially at right angles to the axis of the arched wall itends.
 12. A molded panel as claimed in claim 10 characterized in thatsaid arched wall formation whose axis is substantially at right anglesto said arched wall spanning said spaced mounting means is provided withan internal arcuate groove adjacent one end thereof.
 13. A moldedcladding panel having an outer profiled surface and having an underside,said underside having spaced parallel elongated depending tongues, eachsaid tongue having a plurality of integral barbs spaced along a lengthof said tongue and extending upwardly from a lower end of said tongue atan acute angle thereto, said barbs being resiliently compressibletowards said tongue and said panel having means for interengagingadjoining mating panels.
 14. A molded cladding panel having an outerprofiled surface and having an underside, said underside having at leastone elongated bearing surface and at least one elongated dependingtongue projecting below said bearing surface and substantiallyperpendicular thereto, said tongue having a plurality of integral barbsspaced along a length of said tongue and extending upwardly fromadjacent a lower end of said tongue at an acute angle thereto, and saidbarbs being resiliently compressible towards said tongue.
 15. A moldedcladding panel as claimed in claim 14 having spaced parallel elongatedbearing surfaces and spaced parallel elongated depending tonguesprojecting below said bearing surfaces and substantially perpendicularthereto, each said tongues having a plurality of said integral barbsspaced along the length thereof and extending upwardly from adjacent thelower end tongue at an acute angle thereto, and said barbs beingresiliently compressible towards said tongue.
 16. A molded claddingpanel as claimed in claim 15 in which said tongues project from saidbearing surfaces.
 17. A molded cladding panel as claimed in claims 15 or16 in which said outer profiled surface comprises arched walls archingbetween said spaced parallel bearing surfaces.
 18. A molded claddingpanel as claimed in claims 15 or 16 in which said tongues are planar andsaid integral barbs comprise material displaced out of said tongues. 19.A molded cladding panel as claimed in claim 14 having an ultra violetresistant coating applied thereto.
 20. A molded cladding panel asclaimed in claim 14 in which said barbs are formed by displaced tonguematerial.
 21. A molded cladding panel as claimed in claim 14 having aplurality of spaced upwardly projecting integral nibs on the outerprofiled surface thereof.
 22. A tiled roof overlying a roof structurewhich slopes upwardly to a ridge, said tiled roof comprising a pluralityof keeper members having undercut slots secured to said roof structureand extending up the slope thereof, a plurality of molded/roof panelshaving profiled upper surfaces and elongated bearing surfaces on anunderside of said panels resting on said keeper members, said panelshaving elongated planar tongues depending from said elongated bearingsurfaces projecting into said keepers, said planar tongues having aplurality of spaced barbs at their lower ends, and said barbs beinginclined upwardly at an acute angle to said tongues to lock said tongueinto said undercut slots, said panels being interfitted to provide airpassages running up to the ridge and an air passage at fight anglesthereto running along the ridge and means for closing the ends of saidpassages.
 23. A tiled roof as claimed in claim 22 in which the meansclosing the ends of said passages comprise plastic screens.